Flexible tonneau cover assembly

ABSTRACT

A flexible tonneau cover assembly includes a pair of side rails positioned on the side wall of a cargo box of a vehicle. A first element is received in the first side rail having a projection extending laterally inward from the first side rail. A second element is received in the second side rail having a laterally inward facing latch receptacle. A front rail includes a first end having an opening for receiving the projection of the first sliding element and a second end having a latch receivable by the latch receptacle of the second sliding element. The tonneau cover is removable by rolling it up, disengaging the latch from the laterally inward facing latch receptacle, lifting the second end of the front rail from the second element, and removing the first end of the front rail from the projection of the first element.

TECHNICAL FIELD

The embodiments described related to the field of tonneau covers forvehicles, and more particularly to assemblies and methods for installingand removing the tonneau cover from the vehicle.

BACKGROUND

Tonneau covers are generally used to cover the cargo box of a vehicle,such as a pick-up truck. A typical tonneau cover includes a cover sheetmade of a flexible, waterproof material, and a frame structure to whichthe cover sheet is removably attached. Such tonneau cover assemblies canbe problematic. For example, such frame structures often extend into thecargo space, and some covers can be opened from the exterior of thecargo box even with the tailgate closed. Additionally, sealing of thecargo box from water may be problematic.

APPLICATION SUMMARY

The features and advantages described in the specification are not allinclusive and, in particular, many additional features and advantageswill be apparent to one of ordinary skill in the art in view of thedrawings, specification, and claims. Moreover, it should be noted thatthe language used in the specification has been principally selected forreadability and instructional purposes, and may not have been selectedto delineate or circumscribe the inventive subject matter.

According to one aspect, a flexible tonneau cover assembly includes afirst side rail positioned on a first side wall of a cargo box of avehicle having a first element received in the first side rail, thefirst element having a projection extending laterally inward from thefirst side rail, a second side rail positioned on a second side wall ofa cargo box of a motor vehicle, the second slide rail including a secondelement received in the second side rail, the second element having alaterally inward facing latch receptacle, a front rail including a firstend having an opening for receiving the projection of the first slidingelement and a second end having a latch receivable by the latchreceptacle of the second sliding element, and the tonneau cover attachedto the front rail and extendable to cover the cargo box of the vehicle.

According to another aspect, a flexible tonneau cover assembly includesa first side rail positioned on a first side wall of a cargo box of avehicle, the first side rail including a first sliding element slidablyreceived in the first side rail, the first sliding element having aprojection extending laterally inward from the first side rail, a firstspring block inserted within the first side rail, and a first springlocated between the first sliding element and the first spring block inthe first side rail. The assembly also includes a second side railpositioned on a second side wall of the cargo box of the vehicle, thesecond slide rail including a second sliding element slidably receivedin the second side rail, the second sliding element having a laterallyinward facing latch receptacle, a second spring block inserted withinthe second side rail, and a second spring located between the secondsliding element and the second spring block in the side rail. A frontrail includes a first end having an opening for receiving the projectionof the first sliding element and a second end having a latch receivableby the latch receptacle of the second sliding element. The latch furtherincludes a latch base disposed in the front rail, a sloped engagementsurface for engaging the latch receptacle of the second element, and aspring biasing the latch base and sloped engagement surface laterallyoutward from the front rail. The assembly further includes a tonneaucover attached to the front rail and extendable to cover the cargo boxof the vehicle.

According to yet another aspect, a method of removing a tonneau coverincludes the steps of rolling up the flexible tonneau cover to the frontrail, disengaging the latch from the laterally inward facing latchreceptacle, lifting the second end of the front rail from the secondelement, and removing the first end of the front rail from theprojection of the first element.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is rear perspective view of a portion of a vehicle with aflexible tonneau cover assembly.

FIG. 2 is a perspective exploded view of the flexible tonneau coverassembly.

FIG. 3 is rear perspective view of a vehicle with the flexible tonneaucover assembly in a closed position.

FIG. 4 is a cross-section of the flexible tonneau cover assembly of FIG.3 along line A-A.

FIG. 5 is rear perspective view of the vehicle with the flexible tonneaucover assembly in an open position.

FIG. 6 is a perspective view of a sliding element for use with theflexible tonneau cover assembly.

FIG. 7 is a perspective view of a first sliding element inserted into afirst side rail of the flexible tonneau cover assembly.

FIG. 8 is a perspective view of a second sliding element inserted into asecond side rail of the flexible tonneau cover assembly.

FIG. 9 is a cross-section of the first sliding element inserted into thefirst side rail of the flexible tonneau cover assembly of FIG. 7 alongline B-B.

FIG. 10 is a cross-sectional view of a front rail of the flexibletonneau cover assembly.

FIG. 11 is a perspective view of an embodiment of the flexible tonneaucover assembly in which the flexible tonneau cover is rolled up.

FIG. 12 is a cross-section of the flexible tonneau cover assembly ofFIG. 11 along line C-C.

FIG. 13 is a cross-sectional view of the front rail of the flexibletonneau cover assembly with a strap in a loose position.

FIG. 14 is a cross-sectional view of the front rail of the flexibletonneau cover assembly with a strap in a clipped position.

FIG. 15 is a perspective view of a first end the front rail engaged witha sliding element of the flexible tonneau cover assembly.

FIG. 16 is a cross-section of the flexible tonneau cover assembly ofFIG. 15 along line D-D.

FIG. 17 is a cross-section of a second end of the front rail of theflexible tonneau cover assembly including a latch engaged with thesecond sliding element.

FIG. 18 is a transparent perspective bottom view of a portion of thefront rail with a latch handle.

FIG. 19 is a cross-sectional view of the latch within the front rail.

FIG. 20 is a perspective bottom view of the portion of the front railwith the latch handle.

FIG. 21 is rear view of a portion of the rolled up flexible tonneaucover.

FIG. 22 is a top view of the first front rail engage with the firstsliding element and a gap seal therebetween.

FIG. 23 is a perspective view of the first end of the front rail withthe gap seal.

FIG. 24 is a perspective view of the gap seal.

The figures depict various embodiments for purposes of illustrationonly. One skilled in the art will readily recognize from the followingdiscussion that alternative embodiments of the structures and methodsillustrated herein may be employed without departing from the principlesof the embodiments described herein.

DETAILED DESCRIPTION

As shown in FIG. 1, a vehicle 5 is provided that includes a cargo box 10defined by a first side wall 11, a second side wall 12, a rearward end13 including a tailgate 14, a forward end 15 including a front wall 16,and a bed 17. In general, as shown in FIGS. 1 and 2, a flexible tonneaucover assembly 20 is provided that includes a first side rail 25positioned on or adjacent an upper surface 30 of the first side wall 11,a second side rail 35 positioned on or adjacent an upper surface 37 ofthe second side wall 12, a front rail 40 positioned at the forward end15 of the cargo box 10, a rear rail 45 positioned at the rearward end 13of the cargo box 10, and a flexible tonneau cover 50. As shown in FIGS.3 and 4, the flexible tonneau cover 50 includes a forward end 51 securedto the front rail 40, a rearward end 52 secured to the rear rail 45, afirst side 53 that extends from the forward end 51 of the flexible cover50 to the rearward end 52 of the flexible cover 50, a second side 54that extends from the forward end 51 of the flexible cover 50 to therearward end 52 of the flexible cover 50, a downwardly facing surface56, and an upwardly facing surface 57. The rear rail 45 is movablebetween a closed position as shown in FIG. 3 and an open position asshown in FIG. 5.

As shown in FIGS. 6-9, the front rail 40 may be biased by a separatetensioning system 100 toward the forward end 15 of the cargo box 10. Thetensioning system 100 may include a first sliding element 102 that ismovably secured to a forward end 106 of the first rail 25, shown in FIG.2, and a second sliding element 104 movably secured to a forward end 108of the second rail 35. The sliding elements 102, 104 are biasedlongitudinally forward from the forward ends 106, 108 of the respectiveside rails 25, 35 by, for example, a spring 110 located within each ofthe side rails 25, 35.

A shoulder bolt 112, or any other suitable fastener such as a screw orrivet, may be inserted through a slot 114 in the first side rail 25 andis received in a rearward portion 116 of the first sliding element 102that is positioned inside the forward end 106 of the first side rail 25.The shoulder bolt 112 and the slot 114 serve to movably secure thesliding element 102 to the first side rail 25 and allow for the range ofmovement of the first sliding element 102 to be limited by the length ofthe slot 114. A shoulder bolt 112 may also be inserted through a slot124 in the second side rail 35 and is received in a rearward portion 126of the second sliding element 104 that is positioned inside the forwardend 108 of the second side rail 35. The shoulder bolt 112 and the slot124 serve to movably secure the second sliding element 104 to the secondside rail 35 and allow for the range of movement of the second slidingelement 104 to be limited by the length of the slot 124.

Each spring 110 is further attached or fixedly inserted into a springblock 128. Each spring block 128 in turn rests against a stay 120located within each of the side rails 25, 35 that prohibits the springblock 118 and attached spring 110 from receding into the side rails 25,35. Each spring block 128 may also include a fastener 130, such as ascrew, bolt, or any other suitable fastener, that attaches each thespring block 128 to the respective side rails 25, 35.

FIG. 9, which is a cross section along line B-B in FIG. 7, illustratesone embodiment of the sliding element 102 which includes an extension132 that is inserted within the spring 110. The extension 132 ensuresthe sliding element 102 remains seated within the spring 110.

As illustrated in greater detail FIG. 10, the forward end 51 of theflexible tonneau cover 50 is attached to the front rail 40 by a retainer134 or any other suitable method known to one skilled in the art, andthe rearward end 52 of the flexible tonneau cover 50 is attached to therear rail 45 as shown in FIGS. 3-4.

As illustrated in FIG. 11, the flexible tonneau cover 50 may in turn berolled up around the rear rail 45 in a longitudinally forward directionuntil the flexible tonneau cover 50 and the rear rail reach 45 the frontrail 40. The flexible tonneau cover 50 is equipped with fasteners 136 ofthe kind known to those skilled in the art.

With respect to FIGS. 11-14, one embodiment of the fastener 136 isdisclosed. When the flexible tonneau cover 50 is rolled up, at least onestrap 140, which includes a first strap portion 142 attached to alongitudinally rearward side 150 of the front rail 40 with a male clip152 pulled tight and inserted into a second strap portion 144 with afemale clip 154 attached to the forward end 51 of the flexible tonneaucover 50 and the longitudinally forward side 160 of the front rail 40.When the flexible tonneau cover 50 is unrolled, illustrated in FIGS.13-14, the first strap portion 142 may be allowed to dangle as shown inFIG. 13, or may be secured by a clip 162 to prevent rattling as shown inFIG. 14. In the embodiment illustrated in FIG. 11, the rolled flexibletonneau cover 50 has two straps 140.

Referring again to FIGS. 6-7, the first sliding element 102 may includea projection 200 that extends laterally inward from the body 202 of thefirst sliding element 102. The projection 200 may extend inward between2-10 cm, preferably about 5-6 cm. As illustrated in FIGS. 15-16, Theforward rail 40 includes a female first end 204 designed to receive theprojection 200 that extends laterally inward from the first slidingelement 102 when the front rail 40 is installed. The distal end 206 ofprojection 200 may also include a sloped distal surface 208 on the lowerhalf of the distal end 206 of the projection 200 to allow the front rail40 to become engaged with the projection 200 at an angle α between30-60°. As illustrated, the lower half of the distal surface 208 has aslope of approximately 45°. The projection 200 may be a solid piece, oras illustrated in FIG. 16, the projection 200 may have a hollow centralportion 210 to reduce weight.

As illustrated in FIG. 8, the second sliding element 104 may include areceptacle 220 in the body 222 of the second sliding element 104 openedlaterally inward from the body 222 of the second sliding element 104. Asillustrated in FIGS. 17-20, the front rail 40 has a second end 250 witha latch 252. The latch 252, as shown in FIG. 17, includes a base 254 andupwardly and laterally outward sloping engagement surface 256. As thefront rail 40 is installed into the receptacle 220 in the body 222 ofthe of the second sliding element 104, the engagement surface 256engages with the upper surface 258 of the second sliding element 104. Asthe engagement surface 256 is pushed downward, the engagement surface256 forces the base 254 to move laterally inward into the body 260 ofthe front rail 40, pushing against a latch spring 262 that is biasedlaterally outward toward the second end 250 of the front rail 40. Whenthe distal end 264 of the engagement surface 256 passes the uppersurface 258 of the second sliding element 104, the latch spring 262pushes the sloped surface 256 outward into the receptacle 220, and thedistal end 264 of the engagement surface 256 engages with an innersurface 266 of the receptacle 220 in the second sliding element 104,creating an interference fit that prohibits removal of the latch 252from the receptacle 220. In the illustrated embodiment, the springconstant of the latch spring 262 is between 1000-1300 N/m, and morespecifically 1140 N/m.

A handle 270 is attached to the base 254 to disengage the latch 252 fromthe receptacle 220. The handle 270 may be attached to the base 254through a slot 272 in the front rail 40 by any suitable attachmentmethod. In the embodiment illustrated in FIGS. 18-19 the handle isattached by screw 274. The motion of the handle 270 may be limited bythe dimensions of the slot 272 to prevent damage to the spring 262. Inthe embodiment illustrated in FIG. 19, the movement of the base 254 maybe limited by the presence of a stop 290 to protect the spring 262.Additionally, lateral movement of the handle itself is illustrated inthe embodiment illustrated in FIGS. 18, 20-21. The slot 272 is locatedon a bottom surface 276 of the front rail 40 to prevent debris fromentering the front rail 40 which may inhibit the function of the latch252. The handle 270 wraps around the outer surface 278 of front rail 40such that the distal end 282 of the handle 270 extends rearward of therear side 280 of the front rail 40. The distal end 282 of the handle 272may include a plastic or rubber cover 284 to ease engagement of thehandle 270 by a user. The positioning of the distal end 282 of thehandle 270 provides an ergonomically advantageous position for the user,and also limits exposure of the handle to cargo in the cargo box 10 ofthe vehicle 5.

When the front rail 40 is engaged with the sliding elements 102, 104,and the rear rail 45 is placed in the closed position, as illustrated inFIGS. 3-4, the springs 110 push the sliding elements 102, 104 and thefront rail 40 toward the forward end 15 of the cargo box 10 to apply adesired amount of tension in the flexible cover 50 between the frontrail 40 and the rear rail 45. In the illustrated embodiment, the springs110 have a spring constant between 7500-8500 N/m, and more specifically7880 N/m. The springs 110 ensure that flexible tonneau cover 50 remainstaut in the event of elongation or shrinkage, depending on variableweather conditions, such as wet versus dry conditions, warm versus coldair temperatures, or natural changes to the material related to age andusage. With the flexible tonneau cover system 20, the flexible tonneaucover 50 may be maintained taut within variations in the length of thefabric of +/−15 mm.

To remove the tonneau cover assembly 20, the tonneau cover 50 is rolledup and secured as illustrated in FIGS. 11-12. The front rail 40, withthe tonneau cover 50 rolled up and secured as discussed above, isremoved by the user disengaging the latch 252 by pushing the handle 270,removing the engagement surface 256 from the receptacle 220, lifting thesecond end 250 of the front rail 40, and pulling the front rail 40 offof the projection 200 of the first sliding element 102. Therefore, thisdesign allows for installation and removal of the tonneau cover assembly20 by a single person without the use of tools.

Due to the movement of the sliding elements 102, 104, a gap seal 300 isprovided to provide a seal between cargo box 10 and the upper surfaces30, 37 of the side wall 11, 12 of vehicle 5 in the area of the slidingelements 102, 104. FIGS. 22-24 illustrate one embodiment of the gap seal300 to provide a seal between the front rail 40 and the sliding element102. A second, mirror-image of the gap seal 300 is also provided on thesecond side of the front rail 40 for sealing against sliding element104. The gap seal 300 seals a gap 302 along the sliding element 102 inboth horizontal and vertical planes. The gap seal 300 is a unique rubbermolded part that resides between the front rail 40 and the slidingelement 102. The gap seal 300 reduces water access to the cargo box 10by sealing both a vertical plane and horizontal plane using a system oflips 304, 306, 308. The bottoms 314, 316, 318 of the lips 304, 306, 308contact and seal against a horizontal plane formed by the upper surface30 of the side wall 11. Additionally, the lips 304, 306, 308 sealagainst the sliding element 102. The lips 304, 306, 308 contain reliefnotches 320 in the bottoms 314, 316, 318 of the lips 304, 306, 308 sothat the lips 304, 306, 308 can bend in two directions, longitudinallyforward and rearward, for improved sealing. The gap seal 300 includes anextension 322 that is seated in the front rail 40, and the gap seal 300remains with the front rail 40 when the tonneau cover assembly 20 isremoved. The gap seal 300 may be applied to seal a gap between any fixedelement and sliding element that are on top of a base element.

Reference in the specification to “one embodiment” or to “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiments is included in at least oneembodiment. The appearances of the phrase “in one embodiment” or “anembodiment” in various places in the specification are not necessarilyall referring to the same embodiment.

In addition, the language used in the specification has been principallyselected for readability and instructional purposes, and may not havebeen selected to delineate or circumscribe the inventive subject matter.Accordingly, the disclosure of the embodiments is intended to beillustrative, but not limiting, of the scope of the embodiments, whichis set forth in the claims.

While particular embodiments and applications have been illustrated anddescribed herein, it is to be understood that the embodiments are notlimited to the precise construction and components disclosed herein andthat various modifications, changes, and variations may be made in thearrangement, operation, and details of the methods and apparatuses ofthe embodiments without departing from the spirit and scope of theembodiments as defined in the appended claims.

What is claimed is:
 1. A flexible tonneau cover assembly, comprising: afirst side rail positioned on a first side wall of a cargo box of avehicle, the first side rail comprising: a first element received in thefirst side rail, the first element having a projection extendinglaterally inward from the first side rail; a second side rail positionedon a second side wall of the cargo box of the vehicle, the second sliderail comprising; a second element received in the second side rail, thesecond element having a laterally inward facing latch receptacle; afront rail, comprising: a first end having an opening for receiving theprojection of the first sliding element; and a second end having a latchreceivable by the latch receptacle of the second sliding element; atonneau cover attached to the front rail and extendable to cover thecargo box of the vehicle.
 2. The flexible tonneau cover assembly ofclaim 1 further comprising: a rear rail attached to a tailgate of thevehicle, the tailgate defining a rear end of the cargo box, wherein thetonneau cover is detachably connected to the rear rail.
 3. The flexibletonneau cover assembly of claim 2 wherein the tonneau cover may bedetached from the rear rail and rolled up to the front rail.
 4. Theflexible tonneau cover assembly of claim 3 further comprising: at leastone strap for the securing the tonneau cover to the front rail.
 5. Theflexible tonneau cover assembly of claim 4 wherein the latch furthercomprises: a latch base disposed in the front rail; a sloped engagementsurface for engaging the latch receptacle of the second element; aspring biasing the latch base and sloped engagement surface laterallyoutward from the front rail.
 6. The flexible tonneau cover assembly ofclaim 5 wherein a spring constant of the spring is between 1000-1300N/m.
 7. The flexible tonneau cover assembly of claim 6 wherein thespring constant of the spring is 1140 N/m.
 8. The flexible tonneau coverassembly of claim 5 wherein the latch further comprises: a handle forretracting the sloped engagement surface from the latch receptacle; anda stay in the handle for limiting the laterally inward motion of thelatch base.
 9. The flexible tonneau cover assembly of claim 8 whereinthe handle is attached to the bottom of the latch base.
 10. The flexibletonneau cover assembly of claim 9 wherein the handle extends out of aslot in the bottom of the front rail.
 11. The flexible tonneau coverassembly of claim 10 wherein the handle extends along a bottom surfaceof the front rail, curves around to a side surface of the front rail,and extends longitudinally rearward from the front rail.
 12. Theflexible tonneau cover assembly of the claim 11 wherein the handlefurther comprises: a user engagement surface covering a distal end ofthe handle.
 13. A flexible tonneau cover assembly, comprising: a firstside rail positioned on a first side wall of a cargo box of a vehicle,the first side rail comprising: a first sliding element slidablyreceived in the first side rail, the first sliding element having aprojection extending laterally inward from the first side rail; a firstspring block inserted within the first side rail; and a first springlocated between the first sliding element and the first spring block inthe first side rail; a second side rail positioned on a second side wallof the cargo box of the vehicle, the second slide rail comprising; asecond sliding element slidably received in the second side rail, thesecond sliding element having a laterally inward facing latchreceptacle; a second spring block inserted within the second side rail;and a second spring located between the second sliding element and thesecond spring block in the side rail; a front rail, comprising: a firstend having an opening for receiving the projection of the first slidingelement; and a second end having a latch receivable by the latchreceptacle of the second sliding element, the latch further comprising:a latch base disposed in the front rail; a sloped engagement surface forengaging the latch receptacle of the second element; and a springbiasing the latch base and sloped engagement surface laterally outwardfrom the front rail; and a tonneau cover attached to the front rail andextendable to cover the cargo box of the vehicle.
 14. The flexibletonneau cover assembly of claim 13 further comprising: a rear railattached to a tailgate of the vehicle, the tailgate defining a rear endof the cargo box, wherein the tonneau cover is detachably connected tothe rear rail.
 15. The flexible tonneau cover assembly of claim 14wherein the tonneau cover may be detached from the rear rail and rolledup to the front rail.
 16. The flexible tonneau cover assembly of claim15 further comprising: at least one strap for the securing the tonneaucover to the front rail.
 17. The flexible tonneau cover assembly ofclaim 16 wherein the latch further comprises: a handle for retractingthe sloped engagement surface from the latch receptacle; and a stay inthe handle for limiting the laterally inward motion of the latch base.18. The flexible tonneau cover assembly of claim 17 wherein the handleis attached to the bottom of the latch base and extends out of a slot inthe bottom of the front rail.
 19. The flexible tonneau cover assembly ofclaim 18 wherein the handle extends along a bottom surface of the frontrail, curves around to a side surface of the front rail, and extendslongitudinally rearward from the front rail.
 20. A method of removing aflexible tonneau cover from a vehicle, the vehicle having a flexibletonneau cover assembly comprising a first side rail positioned on afirst side wall of a cargo box of the vehicle having a first elementreceived in the first side rail, the first element having a projectionextending laterally inward from the first side rail, a second side railpositioned on a second side wall of a cargo box of the vehicle, thesecond slide rail including a second element received in the second siderail, the second element having a laterally inward facing latchreceptacle, a front rail including a first end having an opening forreceiving the projection of the first sliding element and a second endhaving a latch receivable by the latch receptacle of the second slidingelement, and the tonneau cover attached to the front rail and extendableto cover the cargo box of the vehicle, the method comprising the stepsof: rolling up the flexible tonneau cover to the front rail; disengagingthe latch from the laterally inward facing latch receptacle; lifting thesecond end of the front rail from the second element; and removing thefirst end of the front rail from the projection of the first element.